Propylene oxide Reactions

Similarly, carbon disulfide and propylene oxide reactions are cataly2ed by magnesium oxide to yield episulftdes (54), and by derivatives of diethyUiac to yield low molecular weight copolymers (55). Use of tertiary amines as catalysts under pressure produces propylene trithiocarbonate (56). 

The simple epoxides are sensitive to moisture levels in the wood during reaction (82). The propylene oxide reaction system seems to be the most affected by moisture, as is shown by high weight losses by extraction of nonbonded chemical and by losses in ASE. The butylene oxide system is less sensitive to moisture, but still results in formation of large amounts of nonbonded glycols. 

Other major industrial applications for hydrogen peroxide include the manufacture of sodium percarbonate and sodium perborate, used as mild bleaches in laundry detergents. It is used in the production of certain organic peroxides such as dibenzoyl peroxide, used in polymerisations and other chemical processes. Hydrogen peroxide is also used in the production of epoxides such as propylene oxide. Reaction with carboxylic acids produces a corresponding peroxy acid. Peracetic acid and meta-chloroperoxybenzoic acid (commonly abbreviated mCPBA) are prepared from acetic acid and /weto-chlorobenzoic acid, respectively. The latter is commonly reacted with alkenes to give the corresponding epoxide. 

An example of this t3T)e of reaction which does not produce a byproduct is the production of allyl alcohol from propylene oxide ... 

The Reaction. Acrolein has been produced commercially since 1938. The first commercial processes were based on the vapor-phase condensation of acetaldehyde and formaldehyde (1). In the 1940s a series of catalyst developments based on cuprous oxide and cupric selenites led to a vapor-phase propylene oxidation route to acrolein (7,8). In 1959 Shell was the first to commercialize this propylene oxidation to acrolein process. These early propylene oxidation catalysts were capable of only low per pass propylene conversions (ca 15%) and therefore required significant recycle of unreacted propylene (9—11). 

With the maturing of the propylene oxidation catalyst area, attention in the 1980s was more focused on reaction process related improvements. 

The reaction is very exothermic. The heat of reaction of propylene oxidation to acrolein is 340.8 kJ /mol (81.5 kcal/mol) the overall reactions generate approximately 837 kJ/mol (200 kcal/mol). The principal side reactions produce acryUc acid, acetaldehyde, acetic acid, carbon monoxide, and carbon dioxide. A variety of other aldehydes and acids are also formed in small amounts. Proprietary processes for acrolein manufacture have been described (25,26). 

The stoichiometric and the catalytic reactions occur simultaneously, but the catalytic reaction predominates. The process is started with stoichiometric amounts, but afterward, carbon monoxide, acetylene, and excess alcohol give most of the acrylate ester by the catalytic reaction. The nickel chloride is recovered and recycled to the nickel carbonyl synthesis step. The main by-product is ethyl propionate, which is difficult to separate from ethyl acrylate. However, by proper control of the feeds and reaction conditions, it is possible to keep the ethyl propionate content below 1%. Even so, this is significantly higher than the propionate content of the esters from the propylene oxidation route. 

The sulfuric acid hydrolysis may be performed as a batch or continuous operation. Acrylonitrile is converted to acrylamide sulfate by treatment with a small excess of 85% sulfuric acid at 80—100°C. A hold-time of about 1 h provides complete conversion of the acrylonitrile. The reaction mixture may be hydrolyzed and the aqueous acryhc acid recovered by extraction and purified as described under the propylene oxidation process prior to esterification. Alternatively, after reaction with excess alcohol, a mixture of acryhc ester and alcohol is distilled and excess alcohol is recovered by aqueous extractive distillation. The ester in both cases is purified by distillation. 

Diester/Ether Diol of Tetrabromophthalic Anhydride. This material [77098-07-8] is prepared from TBPA in a two-step reaction. First TBPA reacts with diethylene glycol to produce an acid ester. The acid ester and propylene oxide then react to give a diester. The final product, a triol having two primary and one secondary hydroxyl group, is used exclusively as a flame retardant for rigid polyurethane foam (53,54). 

Albright Wilson s Vircol 82 is a diol mixture obtained by the reaction of propylene oxide and dibutyl acid pyrophosphate (112). The neutral Hquid has an OH number of 205 mg KOH/g and contains 11.3% phosphoms corresponding to the formula shown where x y = 3.4. The product is a mixture of isomers. 

A number of commercial phosphoms-containing polyols have been made by the reaction of propylene oxide and phosphoric or polyphosphoric acid. Some have seen commercial use but tend to have hydrolytic stabiHty limitations and are relatively low in phosphoms content. BASF s Pluracol 684 is a high functionahty polyol containing 4.5% P, sold for Class 11 rigid foam use. 

Urethane Polymers. An important use for glycerol is as the fundamental building block ia polyethers for urethane polymers (qv). In this use it is the initiator to which propylene oxide, alone or with ethylene oxide, is added to produce ttifunctional polymers which, on reaction with diisocyanates, produce flexible urethane foams. Glycerol-based polyethers (qv) have found some use, too, ia rigid urethane foams. 

Certain bacterial strains convert propylene glycol to pymvic acid in the presence of thiamine (15) other strains do the conversion without thiamine (16). Propylene oxide is the principal product of the reaction of propylene glycol over a cesium impregnated siHca gel at 360°C in the presence of methyl ethyl ketone and xylene (17). 

An oxirane process utilizes ethylbenzene to make the hydroperoxide, which then is used to make propylene oxide [75-56-9]. The hydroperoxide-producing reaction is similar to the first step of cumene LPO except that it is slower (2,224,316—318). In the epoxidation step, a-phenylethyl alcohol [98-85-1] is the coproduct. It is dehydrated to styrene [100-42-5]. The reported 1992 capacity for styrene by this route was 0.59 X 10 t/yr (319). The corresponding propylene oxide capacity is ca 0.33 x 10 t/yr. The total propylene oxide capacity based on hydroperoxide oxidation of propylene [115-07-1] (coproducts are /-butyl alcohol and styrene) is 1.05 x 10 t/yr (225). 

Other possible chemical synthesis routes for lactic acid include base-cataly2ed degradation of sugars oxidation of propylene glycol reaction of acetaldehyde, carbon monoxide, and water at elevated temperatures and pressures hydrolysis of chloropropionic acid (prepared by chlorination of propionic acid) nitric acid oxidation of propylene etc. None of these routes has led to a technically and economically viable process (6). 

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